Insulating Container

ABSTRACT

Disclosed herein are examples of an insulating container with a housing constructed at least partially of a fiber reinforced composite material. The composite material may at least partially include a continuous fiber reinforced composite such as continuous fiber reinforced thermoplastic. The composite material may allow for a decrease in the weight of the insulating container, while maintaining or increasing durability. An insulator such as foam or vacuum may be located between a first and second housing of the insulating container to increase the thermal resistance thereof.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 63/057,042, filed Jul. 27, 2020, entitled “INSULATING CONTAINER,” and U.S. Provisional Application No. 63/087,815, filed Oct. 5, 2020, entitled “INSULATING CONTAINER,” all of which are incorporated by reference in their entireties and for all purposes.

TECHNICAL FIELD

The technology disclosed herein relates to insulating containers, and more particularly to insulating containers constructed at least partially from a reinforced composite such as fiber reinforced thermoplastic (“FRTP”). In some embodiments the container may be constructed with a combination of both FRTP and other materials. In some examples the insulated container is constructed at least partially from a fiber reinforced composite and is vacuum insulated.

BACKGROUND

An insulating container may be constructed so the thermal resistance across a boundary, such as a wall of the container, is increased, reducing the heat transfer rate through the wall. A substance that increases the thermal resistance across a boundary is known as an insulator. Common insulators are foam and vacuum. The reduced heat transfer rate aids in preserving the thermal energy of the contents of the container over time. As an example, an insulating container commonly known as a cooler may be used to keep items cool. Other insulating containers may be used to keep items warm.

The inner or outer layers may require mechanical traits such as durability and toughness and are therefore commonly made of metals, polymers such as polyethylene, polyurethane, or other thermoplastics or thermoset plastics.

In order to increase durability, the polymer material for the inner or outer layers of the insulating container requires a certain thickness. As the layer thickness is increased for improved durability or thermal resistance, the weight of the insulating container increases.

The information included in this Background section of the specification, including any references cited herein and any description or discussion thereof, is included for technical reference purposes and is not to be regarded subject matter by which the scope of the present disclosure as defined in the claims.

SUMMARY

Insulating containers are often transported by human power, therefore low weight is highly beneficial. The lower the weight of the insulating container itself, the greater the allowable payload positioned in the container, and generally the increased volume of the contents to be thermally controlled. Aspects of this disclosure relate to the construction of an insulating container that allow for a decrease in the total weight of the insulating container housing, the enhancement of the thermal insulating properties, and/or the maintenance of or increased strength and durability of the container housing.

In some examples an insulated container may be formed from one or more pieces that are joined together by methods such as welding, gluing, bonding, adhering, mechanically attaching, or other similar methods. An insulator such as foam (e.g., open cell or closed cell polyurethane foam, expanded polystyrene foam (e.g., Styrofoam), or the like) or vacuum may be located between inner and outer layers to increase the thermal resistance between an internal cavity of the container and the environment. Such construction may enable the joining of multiple pieces to form the a housing with complex geometry and the use of varying materials. Several examples focus on possible combinations and variations of a plurality of pieces to form the housing. The housing can therefore be designed for desired engineering criteria, cost, aesthetics and the like.

An insulating container in one example includes a housing defining at least one wall, the wall defining an inner and outer layer spaced away from one another by a distance. An insulator may be located within the space between the inner and outer layers. The container housing may include a number of walls having inner and outer layers spaced apart by a distance. The space between the inner and outer walls may define an insulating volume which may be common between one or more walls, or may be discrete for each wall or other desired portion. The walls together define an internal compartment or cavity in which contents are stored, such as a storage compartment. The wall forms a boundary that inhibits thermal losses between the internal compartment and the environment. The outer walls may form an outer housing, and the inner walls may form an inner housing

In some examples, technology disclosed herein relates to insulating containers with a housing that may be constructed at least partially of a fiber reinforced composite material, such as a continuous fiber reinforced thermoplastic (CFRTP). In some examples the outer housing may be include fiber reinforced composite material while the inner housing may include non-fiber reinforced material. In some embodiments the fiber reinforced composite material varies in thickness.

Other examples include a housing using a vacuum as an insulator. The use of a vacuum as an insulator introduces forces due to the pressure differential with the atmosphere which the housing must resist. In one example, the housing includes a valve structure used to apply vacuum to the insulating volume within the housing. This valve structure is then closed (e.g., formed shut) to allow the structure to maintain the internal vacuum. The valve structure may be openable, so as to adjust the level of vacuum in the in the insulation compartment 12. In another example the housing includes a spacer structure, such as for example, rib supports, between the inner and outer housings to resist the external force of the atmosphere. In another example the housing has at least one non-planer surface that resists the external force of the atmosphere. The non-planar surface in one example may be formed in an outer layer, with a curve having a convex shape directed outwardly from the interior of the container. In yet another example, the outer or inner layers of the housing may include dimple or recessed features that enhance the bending strengthen of the layer in which the feature is formed to resists the external force of the atmospheric pressure. In some examples where the insulator is vacuum, a reactive material may be placed in the vacuum for the purposes of maintaining the vacuum. Such material is commonly known as a getter. A getter may react, adsorb, absorb, or otherwise neutralize gases that may be released into the vacuum, such as by off-gassing from one or more portions of the housing, and thereby maintain the vacuum.

In one embodiment, an insulating container including: a first housing; a second housing coupled to the first housing and defining an insulation compartment therebetween; and an insulating material disposed in the insulation compartment, wherein one of the first housing or the second housing defines an internal compartment and is constructed at least partially of a fiber-reinforced thermoplastic including a reinforcing fiber.

Optionally, in some embodiments, the reinforcing fiber includes a carbon fiber.

Optionally, in some embodiments the carbon fiber is continuous.

Optionally, in some embodiments the carbon fiber is non-continuous.

Optionally, in some embodiments the non-continuous carbon fiber includes a chopped fiber bulk molding compound.

Optionally, in some embodiments the reinforcing fiber is includes a glass fiber.

Optionally, in some embodiments the glass fiber is continuous.

Optionally, in some embodiments the glass fiber is non-continuous.

Optionally, in some embodiments the non-continuous glass fiber includes a chopped fiber bulk molding compound.

Optionally, in some embodiments the reinforcing fiber includes an aramid fiber.

Optionally, in some embodiments the aramid fiber is continuous.

Optionally, in some embodiments the aramid fiber is non-continuous.

Optionally, in some embodiments the non-continuous aramid fiber includes a chopped fiber bulk molding compound.

Optionally, in some embodiments one of the first housing or the second housing includes a fiber-reinforced thermoplastic composite and the other of the first housing or the second housing includes a non-fiber reinforced material.

Optionally, in some embodiments the first and second housings include a fiber reinforced thermoplastic composite.

Optionally, in some embodiments the fiber reinforced thermoplastic composite is a continuous fiber reinforced thermoplastic including a continuous fiber.

Optionally, in some embodiments the continuous fiber includes one of carbon, glass, or aramid.

Optionally, in some embodiments the non-fiber reinforced material includes a thermoplastic.

Optionally, in some embodiments the non-fiber reinforced material is a metal.

Optionally, in some embodiments one of the first housing or the second housing includes a plurality of joined pre-formed fiber reinforced thermoplastic sub-structures.

Optionally, in some embodiments the first housing is an inner housing; the second housing is an outer housing, and the inner housing is nested into the outer housing.

Optionally, in some embodiments a portion of the outer housing has a thickness greater than a thickness of the inner housing.

Optionally, in some embodiments the insulating material includes a foam.

Optionally, in some embodiments the insulating material includes a vacuum.

Optionally, in some embodiments the first housing includes a first interior wall and a first bottom wall; the second housing includes a first interior wall and a first bottom wall, and at least one of the first or second interior walls has a draft angle less than or equal to zero relative to a draw direction normal to one of the first or second bottom walls.

Optionally, in some embodiments a pre-formed component is welded to one of the first or the second housing.

Optionally, in some embodiments the pre-formed component includes a carbon fiber bulk molding compound.

Optionally, in some embodiments the pre-formed component includes a hinge mechanism.

Optionally, in some embodiments the pre-formed component includes a clamp mechanism.

Optionally, in some embodiments the pre-formed component includes drain plug mechanism.

Optionally, in some embodiments the pre-formed component includes a wheel mount mechanism.

Optionally, in some embodiments the pre-formed component includes a handle.

Optionally, in some embodiments the pre-formed component includes a foot.

Optionally, in some embodiments the pre-formed component includes a glass fiber bulk molding compound.

Optionally, in some embodiments the pre-formed component includes a hinge mechanism.

Optionally, in some embodiments the pre-formed component includes a clamp mechanism.

Optionally, in some embodiments the pre-formed component includes a drain plug mechanism.

Optionally, in some embodiments the pre-formed component includes a wheel mount mechanism.

Optionally, in some embodiments the pre-formed component includes a handle.

Optionally, in some embodiments the pre-formed component includes a foot.

Optionally, in some embodiments the pre-formed component includes an aramid fiber bulk molding compound.

Optionally, in some embodiments the container includes an internal wall that defines a sub-compartment.

Optionally, in some embodiments the internal wall defines an internal compartment, wherein the internal compartment includes a first temperature zone configured to be held at a first temperature and the sub-compartment defines a second temperature zone configured to be held at a second temperature different than the first temperature.

Optionally, in some embodiments one of the first housing or the second housing are formed of one or more portions.

Optionally, in some embodiments a first portion is joined to the second portion at a flush joint to form a uniform face.

Optionally, in some embodiments one of the first portion or the second portion is formed of a plurality of overlapping prepreg portions, wherein each of the prepreg portions includes a fiber with a longitudinal direction aligned with a normal direction of a perimeter of the first housing or the second housing.

Optionally, in some embodiments the fiber includes one of a carbon fiber, glass fiber, or aramid fiber.

In one embodiment an insulating container includes: a housing enclosing a vacuum, wherein the housing is constructed at least partially of a fiber reinforced thermoplastic and the housing is at least partially non-planar so as to resist an external force of the atmosphere.

In one embodiment an insulating container includes: a housing forming an insulation compartment therein and configured to enclose a vacuum, wherein the housing is constructed at least partially of a fiber reinforced thermoplastic; and the housing includes a spacer between an inner and outer boundary shells so as to resist an external force of the atmosphere.

Optionally, in some embodiments the spacer structure forms an aperture.

In one embodiment an insulating container includes: a first housing; a second housing coupled to the first housing and defining an insulation compartment therebetween, wherein: the insulation compartment contains a vacuum, one of the first housing or the second housing includes a fiber reinforced thermoplastic, and one of the first housing or the second housing includes a curved shape so as to resist an external force of the atmosphere.

A method of forming a housing of an insulating container is disclosed. The method includes: molding a first housing of the insulating container; removing the first housing from a first mold; and remolding the first housing in a second mold to reduce a draft of the housing.

Optionally, in some embodiments the remolding includes applying at least one of heat or pressure to the first housing with the second mold.

Optionally, in some embodiments the first housing includes a spacer, wherein the spacer is oriented on an upper portion of the first housing when the first housing is assembled in the insulating container.

Optionally, in some embodiments the first housing includes a spacer, wherein the spacer is oriented on a lower portion of the first housing when the first housing is assembled in the insulating container.

Optionally, in some embodiments the first housing includes a first group of spacers; the second housing includes a second group of spacers; and the first and second groups of spacers form a staggered pattern of spacers when the first housing is assembled with the second housing.

A method of forming a housing of an insulating container is disclosed. The method includes molding a first portion and a second portion of the insulating container; assembling a first portion of the insulating container to the second portion of the insulating container to reduce a draft of one of the first portion or the second portion; and attaching the first portion to the second portion.

Optionally, in some embodiments attaching the first portion to the second portion includes welding or adhering the first housing to the second housing.

Optionally, in some embodiments the first portion and the second portion form an assembly and a joint between the first portion and the second portion is substantially flush.

Optionally, in some embodiments one of the first or second portions includes a spacer, wherein the spacer is oriented on an upper portion of the respective first or second portion when the respective first or second portion is assembled in the insulating container.

Optionally, in some embodiments one of the first or second portions includes a spacer, wherein the spacer is oriented on a lower portion of the respective first or second portion when the respective portion is assembled in the insulating container.

Optionally, in some embodiments the first portion includes a first group of spacers; the second portion includes a second group of spacers; and the first and second groups of spacers form a staggered pattern of spacers when the first portion is assembled with the second portion.

An embodiment of an insulating container is disclosed. The insulating container includes an interlocking portion including an inner wall and an outer wall coupled to, and spaced apart from, the inner wall, wherein a first insulation chamber is formed between the inner wall and the outer wall; a rim portion coupled to respective upper edges of the inner wall and the outer wall; a base portion including an inner portion and an outer portion spaced apart from the inner portion. The inner wall and the inner portion form an internal compartment, a second insulation chamber is formed between the inner portion and the outer portion, the inner portion and the outer portion are coupled to the respective lower edges of the respective inner wall and outer wall, and the first insulation chamber and the second insulation chamber are in fluid communication with one another to form a third insulation chamber.

Optionally, in some embodiments the third insulation chamber is configured to contain a vacuum.

Optionally, in some embodiments the insulating container includes a lid portion that is selectively attachable to the rim portion to enclose the internal compartment.

Optionally, in some embodiments the lid portion includes an upper portion coupled to a lower portion and forming a fourth insulation chamber therebetween.

Optionally, in some embodiments the fourth insulation chamber is configured to contain a vacuum.

Optionally, in some embodiments at least one of the interlocking portion, the rim portion, the base portion, or the lid portion are constructed at least partially of a fiber-reinforced thermoplastic including a reinforcing fiber.

Optionally, in some embodiments at least one of the interlocking portion, the rim portion, the base portion, or the lid portion is formed of a plurality of overlapping prepreg portions, wherein each of the prepreg portions includes a fiber with a longitudinal direction aligned with a normal direction of a perimeter of the respective portion.

Optionally, in some embodiments at least one of the interlocking portion, the rim portion, the base portion, or the lid portion is formed of a single prepreg portion.

Optionally, in some embodiments the interlocking portion is joined to the base portion at a flush joint to form a uniform face.

Optionally, in some embodiments at least one of the interlocking portion, the rim portion, the base portion, or the lid portion defines a hoop direction and one or more reinforcing fibers are aligned with the hoop direction.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. A more extensive presentation of features, details, utilities, and advantages of the present invention as defined in the claims is provided in the following written description of various embodiments and implementations and illustrated in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an exploded isometric view of an insulating container.

FIG. 2 shows a cross-section of the portion of the insulating container of FIG. 1.

FIG. 3 shows partial exploded view of a subassembly of the insulating container of FIG. 1.

FIG. 4A shows a tool for manufacturing an example of a portion of the insulating container of FIG. 1.

FIG. 4B shows a tool for manufacturing another example of a portion of the insulating container of FIG. 1.

FIG. 5 shows a cross-sections of the tool of FIGS. 4A and 4B.

FIGS. 6A-6C show example cross-sections of portions of the insulating container of FIG. 1.

FIG. 7 shows an isometric view of an inner housing of the insulating container of FIG. 1.

FIG. 8 shows an exploded isometric view of the inner housing of FIG. 7.

FIG. 9 shows an isometric view of a bottom portion of the inner housing of FIG. 7.

FIG. 10 shows an isometric view of a step of joining the bottom portion of the inner housing of FIG. 9 with a side portion of the inner housing of FIG. 7.

FIGS. 11 and 12 shows examples of different joint types as may be used to join portions of the insulating container of FIG. 1.

FIG. 13 shows an isometric view of a top portion of the inner housing of FIG. 7.

FIG. 14 shows a cross section of the inner housing of FIG. 7 taken along line 17-17 of FIG. 16.

FIG. 15 shows an isometric view of another example of an inner housing.

FIG. 16 shows an elevation view of the inner housing of FIG. 13.

FIG. 17 shows a cross-section view of the inner housing of FIG. 15 taken along section line 17-17 FIG. 16.

FIG. 18 shows plan view of the inner housing of FIG. 15.

FIG. 19 shows a section view of the inner housing of FIG. 15 taken along section line 19-19 FIG. 18.

FIG. 20 shows an isometric view of an outer housing of the insulating container of FIG. 11.

FIG. 21 shows an exploded isometric view of the outer housing of FIG. 20.

FIG. 22 shows a cross-section view of the outer housing of FIG. 20 taken along section line 22-22 of FIG. 20.

FIG. 23 shows an elevation view of a partially assembled outer housing FIG. 20.

FIG. 24 shows partial section view of the partially assembled housing of FIG. 23 taken along section line 24-24 of FIG. 23.

FIG. 25 shows an end elevation view of the outer housing of FIG. 20.

FIG. 26 shows a partial section view of the outer housing of FIG. 25 taken along section line 26-26 of FIG. 25.

FIG. 27 shows another example of an outer housing of the insulating container of FIG. 1.

FIG. 28 shows elevation view of the partially assembled outer housing of FIG. 27.

FIG. 29 shows a partial section view of the partially assembled outer housing of FIG. 28 taken along section line 29-29 of FIG. 28.

FIG. 30 shows an elevation view of the outer housing of FIG. 27.

FIG. 31 is partial cross-section of the outer housing of FIG. 27 taken along section line 31-31 of FIG. 30.

FIG. 32 is a partially exploded view of a subassembly of the insulating container of FIG. 1.

FIG. 33 is an isometric of the subassembly of FIG. 32.

FIG. 34 is an elevation view of the subassembly of FIG. 32.

FIG. 35 is a partial section view of the subassembly of FIG. 32 taken along section line 35-35 of FIG. 34.

FIG. 36 is bottom isometric view of the subassembly of FIG. 32.

FIG. 37 is an isometric view of the subassembly of FIG. 32 showing a valve.

FIG. 38 is a partial cross-section view of the subassembly of FIG. 32 taken along section line 35-35 of FIG. 34 including insulating material.

FIG. 39 is an isometric view of a lead of the insulating container of FIG. 1.

FIG. 40 is an exploded view of a top portion and a bottom portion of the list of FIG. 39.

FIG. 41 is an isometric view of the lid of FIG. 39.

FIG. 42 is an elevation view of the lid of FIG. 39.

FIG. 43 this partial section view of the lid of FIG. 39 taken along section line 43-43 of FIG. 42.

FIG. 44 is an elevation view of the lid of FIG. 39.

FIG. 45 is a partial cross-section view of the lid of FIG. 39 taken along section line 45-45 of FIG. 44, showing an insulating material.

FIG. 46 is an exploded isometric view of an assembly of the insulating container of FIG. 1.

FIG. 47 is an isometric view of the insulating container FIG. 1.

FIG. 48 is partial section view of the insulating container of FIG. 1 taken along section line 48-48 of FIG. 47.

FIG. 49 is isometric view of an example of the insulating container of FIG. 1 including another example of a lid.

FIG. 50A is an elevation view of the insulating container of FIG. 49 showing an embodiment of a hinge.

FIG. 50B is an elevation view of the insulating container of FIG. 49 showing an embodiment of a hinge.

FIG. 51 is an isometric view of an example of an insulating container.

FIG. 52 is a schematic view of atmospheric forces that may be applied to the insulating container of FIG. 1 such as when a vacuum is used as the insulating material.

FIG. 53 is a partial section view of insulating container FIG. 51 taken along section line 53-53 showing examples of atmospheric forces that may be applied to the portions of the insulating container.

FIG. 54 shows an example of a dimple suitable for use in a portion of the insulating container of FIG. 1.

FIG. 55 is an isometric view of an example of an insulating container.

FIG. 56 is a cross section of the insulating container of FIG. 55 taken along section line 56-56 of FIG. 55.

FIG. 57 is an isometric view of an interlocking portion suitable for use in an insulating container.

FIGS. 58A-58C are views of the interlocking portion of FIG. 57 showing apertures formed therein.

FIG. 59 is an isometric view of a partial subassembly formed of a plurality of the interlocking portions of FIG. 57.

FIG. 60 is a cross section of the subassembly of FIG. 59 taken along the section line 59-59.

FIG. 61 is an exploded isometric view of an interlocking portion suitable for use in an insulating container.

FIG. 62 is an end view of the subassembly of FIG. 59 including a cap portion.

FIG. 63 is a partially exploded isometric view of an insulating container including one or more interlocking portions.

FIG. 64 is a cross section of an interlocking portion of insulating container of FIG. 87.

FIG. 65A illustrates a method of reducing a draft of a molded part.

FIG. 65B illustrates a method of reducing a draft of a molded part.

FIGS. 66A and 66B is an example of a molded part formed by the method of FIG. 65A.

FIG. 66C is an example of a subassembly formed of the molded part of FIGS. 66A and 66B.

FIGS. 67A and 67B is an example of a molded part formed by the method of FIG. 65B.

FIG. 68A is a plan view of a molded part in a first orientation.

FIG. 68B is a plan view of the molded part of FIG. 68A in a second orientation.

FIG. 68C is an elevation view of the part of FIGS. 68A and 68B.

FIG. 68D is a plan view of a subassembly formed of molded parts in the orientations of FIGS. 68A and 68B.

FIG. 68E is an elevation view of the subassembly of FIG. 68D.

FIG. 68F is an isometric view of a subassembly formed of molded parts in the orientations of FIGS. 68A and 68B.

FIGS. 69A-71C are methods of forming an interlocking portion.

FIGS. 72A-72C are schematics of a method of forming a molded part including one or more prepreg portions.

FIGS. 73A-73D is an example of an insulating container.

FIG. 74 is a schematic of a method of forming a molded part including one or more prepreg portions.

FIG. 75 is an isometric view of an insulating container.

FIG. 76 is a cross section of the insulating container of FIG. 75 taken along line 76-76 of FIG. 75.

FIG. 77 is a cross section of the insulating container of FIG. 75 taken along line 77-77 of FIG. 75.

FIG. 78 is a partial exploded view of lower portions of the insulating container 1500.

FIG. 79 is a partial exploded view of a upper portions of the insulating container 1500.

FIG. 80A is a partial detail view of an upper joint region of the insulating container of FIG. 75 in a first configuration.

FIG. 80B is a partial exploded view of an upper joint region of the insulating container of FIG. 80A.

FIG. 81A is a partial detail view of a lower joint region of the insulating container of FIG. 75.

FIG. 81B is a partial exploded view of the lower joint region of FIG. 81A.

DETAILED DESCRIPTION

Insulating containers disclosed herein may be formed by materials and methods so as to reduce the weight of the insulating container while increasing the insulating capability of the insulating container. In some examples and insulating container may be formed from one or more portions of plate-like, sheet-like, or planar material that are joined together at one or more joints to form a three-dimensional structure. Some portions may have more complex shapes such as seal portions or bottom portions. An insulating container may be at least partially formed of a fiber reinforced composite such as a continuous fiber reinforced thermoplastic. Other materials may be used as well including: neat (non-reinforced) thermoplastics or thermoset plastics; chopped fiber reinforced composites (e.g., randomly oriented mat-based composites or non-continuous fiber); metals; wood or other natural fibers; foams; other suitable materials such as may be joined by the methods disclosed herein to form an insulating container; or combinations of these. In accordance with the various examples provided herein, this construction may offer decreased weight and or improved durability versus existing construction methods and materials. CFRTP will be discussed in detail, however this is not to limit the scope of the disclosure. Various types of fiber reinforced composites could be used including non-continuous fibers such as short-strand reinforced composites, chopped fiber bulk molding compounds. Fiber reinforced composites with thermoset matrices (with either/both continuous or non-continuous fibers) may be used.

Examples of continuous fiber in CFTRP include, but are not limited to, carbon fiber, glass fiber, aramid fiber, or other suitable fibers. Thermoplastic is typically a polymer wherein the former strands are not cross-linked. An example of a thermoplastic in CFTRP includes a polymer such as polycarbonate. A thermoset plastic is typically a plastic where polymer strands are cross-linked such as with molecules of oxygen, sulfur, or the like. An example of a thermoset plastic is polyurethane. The addition of fibers to the composite increases the strength of the material, while allowing for a relatively thin structure, and thus reduced weight. Alternatively, or additionally, self-reinforced thermoplastic (SRTP) materials may be used to construct at least a portion of the housing. Self reinforced polymer composites are fiber reinforced composite materials. The fiber reinforcement in these materials is a highly orientated version of the same polymer from which the matrix is made, such as a polypropylene matrix reinforced with highly oriented polypropylene fibers. See L. Morgan, et al., Self reinforced polymer composites: Coming of age, ICCM International Conferences on Composite Materials (2009), http://www.iccm-central.org/Proceedings/ICCM17proceedings/Themes/Materials/THERMOPLA %20MATRI X %20COMP/INT %20-%20THERMOPL %20MAT %20COMP/ID12.15%20Morgan.pdf, hereby incorporated by reference in its entirety.

CFRTP is commonly found in pre-impregnated tape and sheet formats or “prepreg” that may be formed or joined using thermoforming techniques. The tape or sheets may be layered at varying fiber orientations to optimize mechanical properties in varying directions, and to increase structure thickness. This manufacturing process may be performed robotically, reducing error and human labor, and increasing layer position accuracy and repeatability. This may be referred to as automatic tape laying (ATL). After the tape or sheets have been layered, the prepreg may be formed into the desired shape via common thermoforming techniques. This is often in the form of the material being mechanically forced between a negative and positive tool with the aid of heat and pressure. Some advantages of a prepreg are: prepreg may not require refrigeration; the material may be recyclable; and thermoplastics typically have greater impact strength (e.g. toughness) than other materials, which may be advantageous for an insulating container that may be dropped or slid against an abrasive surface.

After a CFRTP part is formed, it may then be joined by fusion bonding, welding, or other joining methods to another CFRTP or thermoplastic (“TP”) part or create a larger sub-structure, sub-assembly, or structure. Some examples of welding are laser welding, ultrasonic welding, friction stir, and resistance welding. Fusion bonding or welding may reduce or replace mechanical fasteners (e.g., screws, bolts, nails, rivets, and the like) as a joining mechanism thus reducing weight, complexity and the openings in the structure. Another advantage of the fusion bonding or welding technique of the joining process is that it may be performed robotically, reducing error and human labor and increasing layer position accuracy and repeatability.

Common thermoplastic resins that may be suitable for the purposes described herein include: Polyetherketoneketone (PEKK); Polyether ether ketone (PEEK); Polyaryletherketone (PAEK); Polyphenylene sulfide (PPS); Polyethylene terephthalate (PET); Nylon 6-66 (PA6); Polypropylene (PP); and/or High Density Polyethylene (HDPE). TP Tape materials that may be used include TC1320; TC1225; TC1200; TC1100; TC940; TC910; TC960; TC930 and/or bulk molding compounds provided for example at https://www.toraytac.com/products/thermoplastic/bulk-molding-compounds, hereby incorporated by reference in its entirety. Toray is a common supplier of thermoplastic unidirectional (UD tape and woven prepregs), see https://www.toraytac.com/products/thermoplastic/ud-tapes-and-prepregs, hereby incorporated by reference in its entirety.

As discussed in “Fusion Bonding/Welding of Thermoplastic Composites” research paper in The Journal of Thermoplastic Composite Materials, Volume: 17 issue: 4, pages 303-341 Issued Jul. 1, 2004 [1], hereby incorporated by reference in its entirety, this process may include “heating and melting the polymer matrix on the bond surfaces of the components, and then pressing these surfaces together for polymer solidification and consolidation”. This method is particularly common when the final structure's geometry is complex, highly three-dimensional, or an enclosed shape that would not be possible to be easily formed as a single part. In the case of an insulating container, it may be beneficial to break up the form that allows for a large thermally controlled inner cavity, into several sub-pieces that are later joined via fusion bonding or welding. This may allow for a reduction in tooling size, or complexity reducing production costs. Various types of containers may be constructed in a manner described in this disclosure. Various types of containers may include, in total or in part, structural features as described in this disclosure. These products include, for example but not limited to, cooler containers, tumblers or mugs.

FIG. 1 shows an exploded view of an insulated container 10. The insulating container 10 includes a main subassembly housing 300 and a lid 400. Together the subassembly housing 300 and lid assembly 400 form an internal storage compartment 194. The subassembly housing 300 and the lid 400 reduce heat transfer between the environment and the internal storage compartment 194 such that items placed in the internal storage compartment 194 may generally maintain a given temperature, or may change temperature due to thermal energy transfer through the housing at an acceptably slow rate. For example the internal storage compartment 194 may store items that are desired to remain cold such as beverages, meat, dairy products, or other perishables. In another example the internal storage compartment 194 may store items that are meant to remain hot such as cooked foods or similar items. The subassembly 300 and the lid assembly 400 together form an assembly 500 that forms the insulating container 10.

The insulating container shown in FIGS. 1-3 includes a subassembly housing 300 having in this example four lateral side walls 102, 104, 106, and 108 and a bottom side wall 110. The side walls each may each include an inner layer 112 and an outer layer 114 spaced away from one another by a gap or insulation compartment or volume 12. The size of the gap may vary, and may be in the range of 0.1 inches to approximately 2 inches or more. An insulator material may be located within the space formed between the inner and outer layers. The insulation volume 12 which may be common between the one or more walls, or may be separately formed for each wall or a portion of each wall. The walls together define an internal storage compartment or cavity 194 in which contents may be positioned. The wall or walls form a boundary that inhibits thermal losses between the internal compartment and the environment. The outer layer 114 of each lateral side wall and the bottom wall may together form an outer housing 200, as noted herein. The inner layer 112 of each lateral side wall and the bottom wall may together form an inner housing 100, as noted herein The lid 400 may include a housing having an inner layer 116 and an outer layer 118 spaced away from one another by a gap or insulation compartment or volume 14. The lid 400 in this example is configured as a “wall” 120 similar to the walls 102, 104, 106, 108, and 110 except that it is selectively separable to allow access into the internal compartment 194. The lid may be fully separable from the subassembly, or may be attached by a hinge structure to the subassembly 300. The hinge may be formed from short-strand reinforced thermoplastic composite such as chopped fiber bulk molding compounds. Utilizing short-strand thermoplastic composite may allow for more complex three dimensional shapes such as a hinge to be formed. The hinge may be attached via welding which may be performed in the sub-assembly or final assembly phase. Other components such as handles, lid clamps, drain plugs, a wheel mount, a foot, etc. may be pre-formed components that may be post-welded or otherwise attached to a portion of the insulating container.

As shown in FIG. 2, the subassembly housing 300 may include two or more sub-housings such as an inner housing 100 (e.g. an inner layer) and an outer housing 200 (e.g. an outer layer). Likewise, the lid 400 may include two or more housings such as an upper housing 410 and a lower housing 420. The outer housing 200 and the inner housing 100 may form an insulation compartment 12 therebetween. The upper housing 410 and the lower housing 420 of the lid 400 may form an insulation compartment 14 therebetween. An insulating material may be placed in one or both of the insulation compartments 12, 14 between the housings 100, 200 and/or the housings 410 and 420 respectively such as for example a foam material, a fiberglass mat, or a vacuum. As shown in FIG. 3, the inner housing 100 may nest into the outer housing 200 to form the subassembly 300, and thus form the insulation compartment 12 between the outer housing 200 and the inner housing 100.

The housings of the subassembly 300 or the lid 400 of the insulating container 10 may be formed from portions that are joined at one or more joints to form a completed housing. Portions may be formed, such as by thermoforming, to a desired shape. One such method for thermoforming is by a matched press mold using a plug (male) member and a cavity (female) member. For example as seen in FIGS. 4A and 4B, a positive, or plug, tool 2 and a negative, or cavity, tool 3 may be used to form a portion of the material 1 into a shape matching the gap 5 between the fully inserted plug 2 and the cavity 3. As seen in the example of FIGS. 4A and 4B the positive tool 2 has a shape that corresponds to a depression 4 defined by the negative tool 3. FIG. 4A shows an example where the material 1 is a sheet, or layup, such as a single sheet. FIG. 4B shows an example where the material 1 may include one or more sections 1A, 1B, 1C that may be formed from one or more smaller layers of a material like a prepreg tape such as may be deposited by automatic tape laying methods. Tape layers may be individually laid down along in one or several directions and on top of one another, with varying amount of overlay between sections and/or layers. For example, sections 1A, 1B, and 1C may be disposed at varying angles relative to one another, for example to orient fibers within the sections or layers. As seen for example in FIG. 5 when the negative tool 3 and the positive tool 2 are brought together with the material 1 therebetween, the material 1 may be formed into the shape defined by the gap between the positive tool 2 and negative tool 3. Pressure and/or heat may be applied between the tools so as to adequately form the material 1. The material 1 may be held between the tools for sufficient time to form the material to a desired shape. In some examples, a layup may be designed such that excess material 7 such as flashing may be molded with the part. Flashing 7 may be trimmed in a later process such as cutting, machining, routing, milling, or the like.

FIGS. 6A-6C shows examples of different material layups 1, such as materials described herein, that may be used to form portions of the insulating container 10. For example and without limiting the disclosure, the portions may be all or part of the outer layer 114 of the bottom wall 110, or may be the inner layer 112 of the bottom wall 110, or may be the inner layer 116 of the lid 400, or the outer layer 118 of the lid 400. Additionally or separately, the portion may be all or part of the outer layer 114 or inner layer 112 of any of the walls 102, 104, 106, or 108. The term “layer”, as used herein, may include only one layer of a material, or may include a lamina of more than one layer of the same material or different materials. For instance, the outer layer 114 of any of the side walls or bottom walls may be a single layer of a material or may be a lamina of one or more layer of the same or different materials. FIG. 6A shows an example of a material 1 formed of four layers A-1, A-2, A-3, and A-4. The layers of the material of FIG. 6A may be RFTP (continuous or not continuous fibers) materials with fibers at different orientations relative to one another. For example, the layer A-1 may include fibers oriented left and right across the page of FIG. 6A. Layer A-2 may include fibers oriented at an angle, such as 45 degrees to the fibers of layer A-1. Layer A-3 may include fibers oriented in and out of the page of FIG. 6A. Layer A-4 may be a neat polymer resin with no fiber reinforcing. The layers B-1, B-2, and B-3 of FIG. 6B may be similar. The material of FIG. 6C may be a material of a single type such as a CRFTP, or a neat thermoplastic or thermoset plastic, a metal or other suitable materials. FIGS. 6A through 6C are illustrative only. Materials with any orientation of fibers, or no fibers at all, may be used in any layer of any material 1 for use in the insulating container 10. Any suitable number of layers may be used such as two layers, five layers, six layers or more. Certain portions of the insulating container 10 may be made of one type of layered material, while other portions of the insulating container 10 may be made of other types of layered materials. For example a bottom portion of the insulating container configured to be in frequent contact with a support surface such as the ground may be made of more layers or layers with abrasion resistant characteristics so as to avoid damage while in use. Layers may vary in thickness across all or a portion of a layer. For example, a layer may have thicker portions near edges and thinner portions near a middle section, or vice versa. In some examples, a layer of reflective material may be included such as to improve the thermal characteristics of the material.

In certain examples the construction of the insulating container housing uses entirely fiber reinforced composite material. In other examples, the construction of the insulating container uses a combination of both a fiber reinforced composite and a non-fiber reinforced material. The outer housing of the insulating container may be more durable than the inside of the container since it may be exposed to the most physical abuse from its surroundings during use. The outer housing 200 of the insulated container also has a greater surface area than the inner housing 100 and may thus be subjected to greater forces, like atmospheric forces, than the inner housing. A fiber reinforced composite such as CFRTP may be used to construct the outer housing offering greater weight reduction and a more durable structure. A non-fiber reinforced material such as a homogeneous thermoplastic may be used as a more economical option to construct the inner housing 100 where durability is less critical.

FIG. 7 shows an isometric view of an example of a completed inner housing 100, with FIGS. 8-19 showing the assembly structure of examples of the inner housing 100. FIG. 8 shows an exploded view of the examples of the housing shown in FIG. 7. As can be seen in FIG. 8 the inner housing 100 may be made of multiple portions that are joined together to form the completed inner housing 100. For example as shown in FIG. 8, the inner housing 100 includes a first side portion 110, a second side portion 140 opposing the first side portion, a first end portion 120, a second end portion 150 opposing the first end portion, a bottom portion 160, and a top portion 180. Any of the portions 110, 120, 140, 150, 160, or 180 may be formed according to the methods (e.g., such as thermoforming) and of the materials disclosed herein. Some of the portions such as the side portions 110 and 140 may have simple plate-like structures. Other portions such as the end portions 120, 150, the bottom portion 160, or the top portion 180 may have more complicated features.

The side portions 110, 120, 140, 150 and 160 may be panel structures, formed in this example by thin bodies. The panels may each have a first inner face and a second opposing outer face spaced apart by the thickness dimension of the panel. The panels may each be entirely or partially planar, entirely or partially curved in a single plane, entirely or partially curved in multiple planes, and/or a combination. The panels may define peripheral edges defining the shape of the panel, and along which a panel may be at least partially attached to an adjacent panel as noted below.

The opposing side portions 110 and 140 may be formed by panels 117, 147 respectively. The panel 117 may have a first face 115 and an opposing second face 116. The panel 117 may be joined to one or more adjacent panels along edges 111, 112, 113, and 114. The edges 111-114 may join the respect edges of an adjacent panel, such as for example at or close to respective corners formed between the adjacent panels. A panel may be formed by one or more than one body attached together along adjacent edges. The side portion 140 may be the same shape and size as the side portion 110 or may be a different size and shape. In the example shown the side portion 140 is substantially similar to the side portion 110 and includes a body 147. The body 147 has a face 145 and an opposing second face 146. The faces 145 and 146 are joined to one or more adjacent panels along edges 141, 142, 143, 144. In some examples the side portion 110 and the side portion 140 may be mirror images of one another about the midline of the insulating container 10. For example, portion 110 is attached along 111 to portion 150, along edge 114 to panel 160, along edge 113 to portion 120. Note that the corner structure may be formed in one or the other of the adjacent panels so that the corner structure is spaced away from the line of connection between adjacent corners. For an example, see FIG. 8 where corner 127 is formed in portion 120 spaced away from edge 124, which edge 124 is attached to panel 117 along edge 113. The corner structure could be formed in the side panels 117 and 147 as an alternative, or in the bottom panel 160 as desired.

The end portions 120 and 150 may be structures formed by panels 129, 159. The panel 129 of the end portion 120 may have a first outer face 125 an opposing second inner face 126 spaced apart from one another. The faces 125 and 126 may be joined to one or more adjacent panels along edges 121, 122, 123, and 124. The end portion 120 may have corner portions 127 and 128 disposed at either end of the panel. The end portion 150 may have similar faces 155, 156; edges 151, 152, 153, and 154; and corner portions 157 and 158. The corner portions 127, 128, 157, and 158 may serve to transition between the end portions and the side portions in the assembled inner housing 100. The corner portions may also serve to strengthen the structural rigidity of the inner housing 100.

As shown in FIGS. 8 and 9, the bottom portion 160 may be a structure formed by a panel 172. The panel 172 may have an inner face 165 and an opposing outer face 171. The faces 165 and 171 may be joined to one or more adjacent panels along edges 161, 162, 163, and 164. The corners 167, 168, 169, and 170 may be formed in the panel 172 spaced away from respective edges 161, 162, 163, and 164. The corners and 167-170 may be adapted to allow a generally flat or planar attachment with the respective adjacent walls, and may cooperate with respective corners 127, 128, 154, 157 of the end portions 120 and 150. For example, edge 163 of panel 160 may engage with edge 114 of portion 110; edge 162 of panel 160 may engage with edge 153 of panel 159; edge 161 of panel 160 may engage with edge 144 of portion 140; and edge 164 of panel 160 may engage with edge 123 of portion 120.

As best shown in FIGS. 8 and 14, the top portion or rim structure 180 of the inner housing 100 may be a structure formed by a body 195. The body 195 may have wall portions 181, 182, 183, and 184. The wall portions form a frame or ring that at least partially surrounds and defines an aperture 186. The wall portions 181-184 may form a continuous lower edge 198 (best seen in FIG. 14). In this example, where the frame is generally 4-sided, the wall portion 181 may be opposite wall portion 183; and wall portion 182 may be opposite wall portion 184. The wall portions may be joined at respective corner portions 187, 188, 189, and 190. Thus the wall portions and the corner portions may form the open frame that defines the aperture 186. As may be seen best in FIG. 14, the top portion 180 may include a lateral flange portion 191 extending outwardly from the outer side of a raised rim or protrusion 185. A skirt portion 196 descends from an outer end of the flange portion 191, with the free edge portion of skirt 196 defining rim 198 as referenced above. The outer skirt 196 forms an outer edge of the rim structure 180. The raised protrusion or shoulder 185 may extend along all or part of the rim structure 180 to form part of a seal structure (see, e.g., FIG. 48), such as to reduce or substantially prevent the passage of heat energy between the intersection of the lid and the main body of the housing. An inner skirt 197 extends downwardly at an inner edge of the rim structure 180, and terminates at a free end 193 (FIG. 14), which for example may be a bottom edge. The aperture 186 may provide access into the internal storage compartment 194 formed in the inner housing 100 of the insulating container 10.

The rim structure 180 is attached generally along inner skirt 197 to the top of the panel portions 110, 120, 140, 150, and together they form the inner housing 100. For example, the bottom edge 193 is attached at or adjacent to the edge 112 of panel 117, edge 151 of panel 159, edge 142 of portion 140, and edge 121 of panel 129.

The thickness of the panels, such as the inner layer or outer layer or both, made at least partially from the reinforced thermoplastic materials disclosed herein may be between 0.5 mm to 7 mm. The range may be more specifically between 1 mm and 5 mm. Generally the wall thickness may be thinner for a fiber reinforced material compared to material that is not fiber reinforced, because the fiber reinforced material has a generally higher strength per unit weight. This may also may result in an overall lighter container structure given the reduced wall thickness.

The portions of the inner housing 100 (and also including the portions of the outer housing and/or the lid as described below), such as the panels described above, may be joined together at one or more joints. For example as shown in FIG. 10 the portion 110 may be joined to the bottom portion 160 at a joint 101. This joint 101 is similar to the other joints formed between other adjacent panels, or between the panels and the skirt 197 of rim structure 180. The joint 101 may be formed by aligning the lower edge 114 of the side portion 110 with the edge 163 of the bottom portion 160. When the edges 114, 163 are aligned the edges may be joined by any suitable method for example welding, gluing, bonding, or other similar methods. The joined side portion 110 and the bottom portion 160 may form a partial assembly 199 of the inner housing 100. Where the outer layer (such as for the outer housing) or inner layer (such as for the inner housing) may be made of more than one panel or portion of a panel connected together, or where adjacent panels are secured together in forming the inner or outer housing of the container, the panels or portions may be joined together along adjacent edges by plastic welding, or by placing the panels or portions of panels (pre-formed or stamped) to be secured together in a rigid mold (such as a clamshell mold) wherein a bladder is used as internal pressure to help effect the joining. See for example, A. Salomi, et al., Bladder molding of double layers wall fibre reinforced thermoplastic material, ICCM International Conferences on Composite Materials (2009), http://www.iccm-central.org/Proceedings/ICCM17proceedings/Themes/Materials/THERMOPLA %20MATRI X %20COMP/D12.6%20Salomi.pdf, hereby incorporated by reference in its entirety. The tool is heated above glass transition temperature to weld all joints, and then cooled, with the bladder applying pressure to at least the regions of the adjacent panels or portions of panels being joined together.

The multi-piece construction of the container, for example where adjacent panels are joined together not in a rigid mold, is that no draft angle is needed to assist in removing components from a mold form. Therefore the cooler internal compartment may be formed with orthogonal sidewalls and/or bottom walls, which may allow the increase in useable volume for storing contents. Additionally, the cooler internal compartment may be formed with sidewalls and/or bottom walls wherein it defines a larger area at the bottom of the cooler than at the top. As typically constructed, existing coolers may require a draft (smaller area at bottom of cooler than at the top of the cooler container) along the sidewalls due to mold requirements. Additionally, the interior of the internal storage compartment may be customized to include defined walls, compartments, chambers or other features not feasible given existing techniques used for making cooler containers.

Regarding the relatively complex parts and accessories that are mounted on a cooler container, such as hinge components, clamp components, wheel mounts, handles, etc. may be compression molded out of “short-strand” or “chopped fiber bulk molding compound” to allow for more complex 3-dimensional forms and then welded to the inner housing, outer housing, lid or other portion of the cooler container. Attaching these components by welding removes the need for fasteners. Fasteners commonly lead to thermal loss, and may make holding a vacuum difficult where the fastener is positioned through a wall of the insulation compartment (as defined elsewhere herein).

In addition, metal accessories may be installed in or on the thermoplastic housing. A threaded insert, for example may be heated (commonly via ultrasonic energy), and placed into an under-sized hole where the insert is held in place as the thermoplastic cools. An example is an “E-Z Sonic” ultrasonic insert made by E-Z Lok: https://www.ezlok.com/e-z-sonic-ultrasonic-inserts-for-plastic, hereby incorporated herein by reference in its entirety. This method may be simpler and more cost effective than co-molding a metal (e.g., aluminum) insert.

The joints between two or more portions or panels of the insulating container 10 may be formed in a variety of ways, as shown for example in FIGS. 11 and 12. Many possible joint configurations, or combinations of joint configurations, may be used. A simple butt joint is possible however the joint may overlap as in a lap joint. Common joint examples are stepped, tongue and groove, shear, scarf joints, etc. Joints with energy director features may also be used to optimize the joint bond strength. For example as shown in FIG. 11, joint 703 is an example of a step joint between three portions X, Y, Z of the insulating container 10. Joint 705 is another example of a step joint between three portions of the insulating container 10. Joint 707 is yet another example of the step joint between three portions of the insulating container 10. Joint 709 is an example of a scarf joint between three portions. Joint 711 is an example of a butt joint between three portions of the insulating container 10. Joint 712 shown in FIG. 12 is an example of a scarf joint between two portions X and Z of the insulating container 10. Joint 714 is an example of a tongue and groove joint between two portions of the insulating container 10. Joint 716 is an example of a step joint, such as a lap joint, between two portions of the insulating container 10. Joint 718 is an example of a butt joint between two portions of the insulating container 10. Other suitable types of joints may be used.

FIG. 13 shows an example of attaching a top portion 180 to the rest of the assembled structure to form inner housing 100. For example the rim structure 180 may be joined to the rest of inner housing 100 at joint 109 (FIG. 12). Likewise the side portion 140 may be joined to the bottom portion at a joint 103 and to the end portion 150 at a joint 119 (FIG. 13). The end portion 150 may be joined to the side portion 110 at a joint 105. The side portion 110 may be joined to the end portion 120 at a joint 107. The end portion 120 may be joined to the side portion 140 at a joint 130. Any of the joints 101-107 may be any of the types of joints described herein. The joints may be continuous, and may be sealed against fluid passage (including in gaseous and liquid form).

The assembled portions of the inner housing 100 may define the internal storage compartment 194 therebetween. The internal compartment 194 may be adapted to hold certain items that are desired to be kept in a temperature-controlled environment.

FIG. 14 show an example of an assembled inner housing 100. As can be seen in the cross section of FIG. 14, the portions that make up the inner housing 100 may be made of different materials, or have materials with different fiber orientations.

FIGS. 15-19 illustrate an example of an inner housing 100A formed of a single piece of material, such as for example by molding a sheet of thermoplastic material. The inner housing 100A may have substantially similar structural features as the inner housing 100. The inner housing 100A may be made of any suitable material disclosed herein. The inner housing 100A may have a body 110A in the form of a thin wall formed to have features similar to those of the inner housing 100.

FIGS. 20-26 illustrate an example of an outer housing 200. The outer housing 200 may be formed of similar or different materials and with similar or different techniques as the inner housing 100. As shown for example in FIG. 20, the outer housing 200 may include opposing side portions 210 and 240. The outer housing 200 may include opposing end portions 220 and 250. The outer housing 200 may include a bottom portion 260.

The side portions 210, 220, 240, 250 and 260 may be panel structures, formed in this example by thin bodies. The panels may each have a first inner face and a second opposing outer face spaced apart by the thickness dimension of the panel. The panels may each be entirely or partially planar, entirely or partially curved in a single plane, entirely or partially curved in multiple planes, and/or a combination. The panels may define peripheral edges defining the shape of the panel, and along which a panel may be at least partially or entirely attached to an adjacent panel as noted below. This general structure and assembly is similar to that described above for the inner housing 100.

The opposing side portions 210 and 240 may be formed by panels 217, 247 respectively. The panel 217 may have a first face 215 and an opposing second face 216. The panel 217 may be joined to one or more adjacent panels along edges 211, 212, 213, and 214. The edges 211-214 may join the respective edges of an adjacent panel, such as for example at or close to respective corners formed between the adjacent panels. A panel may be formed by one or more than one panel attached together along adjacent edges. The side portion 240 may be the same shape and size as the side portion 210 or may be a different shape. In the example shown, the side portion 240 is substantially similar to the side portion 210 and includes a panel 247. The panel 247 has a face 245, an opposing second face 246, and a lateral flange portion 248. The panel 240 may be joined to one or more adjacent panels along edges 241, 242, 243, 244. Some examples of the side portion 210 and the side portion 240 may be mirror images of one another about the midline of the insulating container 10.

The end portions 220 and 250 may be panel structures formed by a thin body 229, 259. The panel 229 of the end portion 220 may have a first face 225 and an opposing second face 226 spaced apart from one another. The faces 225 and 226 may be joined at edges 221, 222, 223, and 224. The end portion 220 may have corner portions 227 and 228 disposed at either end of the panel. The end portion 250 may have similar faces 255, 256; edges 251, 252, 253, and 254; and corner portions 257 and 258. The corner portions 227, 228, 257, and 258 may serve to transition between the end portions and the side portions in the assembled outer housing 200. The corner portions 257, 258 may also serve to strengthen the structural rigidity of the outer housing 200. The edges 221 and 251 may be disposed on lateral flange portions 230 and 273, respectively.

The bottom portion 260 may be a panel structure formed by a thin body 272. The panel 272 may have an inner face 265 and an opposing outer face 271. The faces 265 and 271 may be joined by edges 261, 262, 266, and 264. The edges 261-264 may be joined by respective corners 267, 268, 269, and 270. The corners 267-270 may be adapted to cooperate with respective corners 227, 228, 257, and 258 of the end portions 220 and 250. An aperture 263 may be formed in the face 265 of the bottom portion 260.

The portions 210, 220, 240, 250, and 260 of the outer housing 200 may be joined at one or more joints similar to those described with respect to the inner housing 100. As shown in FIG. 31, the joined portions of the outer housing form a recess 294 suitable to receive the inner housing 100, such that the inner housing may nest in the outer housing 200. In the assembled outer housing 200, the lateral flange portions 219, 248, 230, 273 may form a continuous flange 280 around a perimeter of the outer housing 200.

For example, panel 217 is attached along edge 211 to portion 250, along edge 214 to panel 260, along edge 213 to portion 220. Note that the corner structure may be formed in one or the other of the adjacent panels so that the corner structure is spaced away from the line of connection between adjacent corners. For an example, see FIG. 21 where corner 227 is formed in portion 220 spaced away from edge 224, which edge 224 is attached to panel 217 along edge 213. The corner structure could be formed in the side panels 210 and 240 as an alternative, or in the bottom panel 260 as desired.

FIGS. 27-31 illustrate an example of an outer housing 200A. The outer housing 200A may be substantially similar to the outer housing 200 but without the lateral flange portions 219, 230, 248, and 273.

FIGS. 32 through 38 show an example of a subassembly 304 at the insulating container 10. The subassembly 300 may be formed when the inner housing 100 is nested into the outer housing 200 as shown in FIG. 32. As shown in FIG. 35, the outer housing 200 and inner housing 100 may be joined at a joint 302 formed between the edge 198 of the upper housing and the flange 280 of the lower housing. The joint 302 may be formed by any method and with any structure disclosed herein. The assembled subassembly 300 is shown in FIG. 33, for example. The subassembly 300 defines an insulation compartment 12 between the inner housing 100 and the outer housing 200. The insulation compartment 12 is suitable for containing an insulating material 306 as shown for example in FIG. 38. Insulating material 306 may be an insulating sheet, mat, or foam substance, or may be a relative vacuum applied to the insulation compartment compared to atmosphere.

The insulating material 306 may be added to the insulation compartment 12 through the aperture 263 or another suitable aperture or apertures. For example when the insulating material is a foam, the foam may be sprayed or inserted into the aperture 263 in order to fill the insulation compartment 12. In some examples, more than one aperture may be formed in the outer housing 200 so as to provide a vent air escaping the insulation compartment 12 as the insulating material 306 is added. Other apertures may be sealed by appropriate valves. In cases where the insulating material 306 is a vacuum, air may be withdrawn from the aperture 263 to create a relative vacuum (compared to atmospheric pressure) with in the insulation compartment 12.

After the insulating material 306 is added to the insulation compartment 12, the insulation compartment 12 may be sealed with a valve 304. The valve 304 may be any suitable structure capable of sealing the insulation compartment 12, such as to contain the insulating material 306, or to maintain the vacuum in cases where the insulating material 306 is a vacuum. In some examples the valve 304 is a section of the material of similar construction to that of the outer housing 200. The valve 304 may be welded or bonded or otherwise attached to the outer housing 200, so as to maintain a seal suitable to contain the insulating material 306.

FIGS. 39 to 45 shown example of a lid 400 suitable for use with the insulating container 10. The lid 400 may include an upper portion 410 and a lower portion 420. The upper and lower portions 410 and 420 may be formed of similar or the same materials as the outer housing 200 and the inner housing 100. The lower portion 420 of the lid 400 may include a body 421 with a planar or plate-like structure. The body 421 may have an inner face 440 and an opposing outer face 444. The body 421 may have an end 426 and an opposing end 430. The body 421 may have a side 424 and an opposing side 428. The sides and edges may be joined at respective corners 432, 434, 436, and 438. The sides, ends and corners 424, 426, 428, 430, 432, 434, 436, and 438 may form a continuous flange 446 around a perimeter of the lower portion 410. The lower portion 420 may have a recess 442 extending away from a face, such as the face 440 or the face 444. The recess 442 may be configured to form part of a seal with the protrusion 185 of the inner housing 100. An aperture 422 may be formed in the body, similar to the aperture 263 of the outer housing 200, such as to place an insulating material in the lid 400. The upper portion 410 of the lid 400 may include a body 417 with a planar or plate-like structure. The body 417 may have an inner face 416 and an opposing outer face 415. The body 417 may have an end 411 and an opposing end 413. The body 417 may have a side 412 and an opposing side 414. The sides and edges may be joined at respective corners 451, 452, 454, 456. The sides, ends and corners 411, 412, 413, 414, 450, 452, 454, and 456 may form a continuous edge 448 around a perimeter of the upper portion 420. The sides, ends and corers may extend away from the face 415 or the face 416.

The upper portion 410 and the lower portion 420 may be joined together to form the lid 400. For example, the upper portion 410 and the lower portion 420 may be joined at a joint 550 formed between the edge 448 and the flange 446. The joint 450 may be formed by any method and with any structure disclosed herein. The upper portion and lower portion of the lid may form an insulation compartment 418 suitable for containing an insulating material 462. The insulating material 462 may be the same insulating material as the insulating material 306, or it may be different. As with the subassembly 300, the insulating material 462 may be added to the insulation compartment 14 of the lid 400 and the lid 400 may be sealed by a valve 460.

FIGS. 46-48 show an assembly 500 including the subassembly 300, the lid 400 and a seal 406. The assembly 500 may form the insulating container 10. As shown for example in FIG. 48, the lid 400 and the subassembly 300 may define the internal storage compartment 194. The seal 406 may be configured to be received between the protrusion 185 of the inner housing and the recess 294 of the lower portion 420 of the lid 400. The seal 406 may form a fluid tight-barrier between the internal compartment and the environment. The seal may be in the form of a gasket, ring, o-ring, or other shape that surrounds a portion of the inner housing 100. The seal 406 may be any suitable material that can form a barrier between the internal storage compartment 194 and the environment. Some example seal materials include: elastomers like rubber, silicone, ethylene propylene diene monomer (“EPDM”), polychloroprene; cork; fiberglass packing; combinations of these; or other materials.

FIGS. 49-50 show an example of an insulating container 10A. The insulating container 10A may be substantially similar in materials and methods of manufacture as the insulating container 10. The insulating container 10A may have the lid 400 pivotally coupled to the subassembly 300 by a pivoting joint 510 such as a hinge, pin, a rod, or the like.

FIGS. 51-53 show an example of an insulating container 600. The insulating container 600 may be substantially similar in materials and methods of manufacture as the insulating container 10 and may be specially adapted to use a vacuum as the insulating material. For example, as shown in FIG. 53. The insulating container 600 may include an inner housing 620 and an outer housing 610. The housings may form in internal compartment 694 as previously described with respect to the insulating container 10. The housings may define an insulation compartment 612 suitable to contain an insulating material such as a vacuum 614. One or more portions of the insulating container 600 may include structures to resist forces 602 imparted to the insulating container 610. For example, the outer housing 610 may include a non-planar portion. A non-planar portion may be shaped to resist atmospheric forces created when the insulation material is a vacuum. For example, the curved portion 616 of the outer housing 610. Curved portions may be added to some or all of the portions of the insulating container 600 such as via a suitable tool 2, 3 such as with thermoforming as described herein. Curved portions may be concave or convex. Curved portions may be hemispherical, elliptical, torispherical, cylindrical, circular, or the like. The curved portion may be corrugated or otherwise have a variable shape across the dimension of the surface to which it is applied. The curved portion(s) may be formed across an entirety of, or only partially on, a side of the outer or inner housing. In some examples, an insulating container may include portion with a circular cross section.

Additionally or alternately, other features such as dimples 618 as shown for example in FIG. 54 may be added to a portion of the insulating container 600.

A structure 620 may be positioned in the insulating compartment 12, 612 to span from an inner wall to an outer wall and maintain a distance there between. The structure 620 may include one or more spacers or ribs included within the insulating compartment 12, 612, such as to further enhance the structural characteristics of the insulating container 600. A spacer 620 may be disposed on an inside wall, such as an inside of the outer housing 200, such as for example the spacer 626. A spacer 620 may be disposed on an outer wall, such as for example an outer wall of the inner housing 100, like the spacer 628. A spacer may bridge between walls, such as the spacer 620. A spacer may be made of one or more materials. For example, the spacer 620 may include a first material 624 to provide structural support to the spacer and a second material 622 to enhance the thermal properties of the spacer 620. For example, the first material 624 may be a CFRTP material and the second material 622 may be an insulator such as a foam, foil, ceramic, silica fibers, ceramic, glass, or the like. In some examples, the relative positions of the first material and the second material may be swapped. Spacers may be attached to the portions of the insulating container 600 such as by welding, bonding, gluing, mechanical attachment, or the like. Spacers, or portions thereof may be integrally formed with the portions of the container 600 such as by an appropriate thermoforming tool. In some examples, a spacer may be held between walls in compression. For example, as a vacuum 614 is formed in the insulation compartment 612, the walls may deform slightly and capture, through compression, one or more spacers.

The vacuum 614 may be formed in an insulating container by a mechanical means such as a vacuum pump. A reactive material or getter may be added to the insulation compartment 612 so as to adsorb, react, or otherwise neutralize gasses that may seep into the insulation compartment 612 such as by off gassing or diffusion. Some example getter materials include barium, aluminum, magnesium, calcium, sodium, cesium, or phosphorus.

Traditional forming techniques such as injection molding or press forming often include a draft or taper in the mold such that the molded part may be easily released from the mold forms. Such manufacturing concerns limit design options and often result in compromises such as an insulating container that tapers from the top, becoming narrower toward the bottom.

FIGS. 55 and 56 show an example of an insulating container 700 made with the methods and/or materials disclosed herein and including an internal compartment 794 made without a draft and may include a larger internal compartment 794 than an internal compartment of a similarly sized insulating container made with traditional methods and materials. For example, the insulating container 700 may have inner portions 710 and outer portions 720 formed such that the internal compartment 794 does not taper from the toward the bottom, or the like. For example, the inner portion 710 may have a side wall 719 and a bottom wall 717. The side wall 719 and bottom wall 178 may be substantially perpendicular to one another. Similarly, the outer portion 720 may include a bottom wall 728 and a side wall 729 which may be substantially perpendicular to one another. In some examples, in the assembled insulating container 700, one or more walls of the inner portion 710 may be substantially perpendicular to one or more walls of the outer portion, and vice versa. In other examples, the insulating container 700 may have portions 710, 720 that taper so as to be wider at the bottom than the top. In some examples, an interior wall may have a draft angle less than or equal to zero relative to a draw direction normal to one of the first or second bottom walls. In some examples, components may be molded with a draft and be subjected to additional processing to change, reduce, or remove the draft as described with respect to FIGS. 65A-66C.

Any insulating container disclosed herein may include one or more internal walls, such as the walls 702 and 704 of the insulating container 700 that form a sub-compartment 706 within the internal compartment 794. Such a sub-compartment 706 may be useful for segregating items to be kept in the temperature controlled environment. For example, the sub-compartment 706 may be suitable to segregate items that should not get wet from ice stored within the main internal compartment 794.

In some examples, an insulating container may include different temperature zones within the internal compartment 794 or segregated therefrom. An insulating container may include internal walls or portions that form a sub-compartment including an internal insulation compartment. For example, as shown in FIG. 56, walls 701, 708, and 709 may form a sub-compartment 740 separated from the main internal compartment 794 by an internal insulation compartment 716. The insulation compartment 716 may be filled with a suitable insulating material 715, which may be any insulating material disclosed herein. A sub-compartment such as the sub-compartment 740 may enable the use of different temperature zones with the insulating container 700. For example, the sub-compartment 740 could contain frozen items (e.g., kept at or below 0° C.), while the main compartment 794 and sub-compartment 706 could contain refrigerated items (above 0° C.). Again, traditional manufacturing techniques may not be suitable for forming such structures. In another example, the sub compartment could contain hot items while the main compartment 794 includes cold items.

The walls 701, 702, 704, 708, and 709 may be formed of any material disclosed herein, such as an FRTP material. The walls may be joined to one another and/or to another portion of the insulating container 700 at one or more joints 730, 732, 734 and using any joining method as disclosed herein.

FIGS. 57-62 show examples of interlocking portions 800, 820 that may be used to form an insulating container, such as the insulating container 900 illustrated for example in FIGS. 63 and 64. An interlocking portion 820 may be formed with the material and/or methods disclosed herein such as thermoforming of an FRTP material. The interlocking portion 800 may include an inner flange 802 and an outer flange 804. The flanges 802, 804 have a web 810 spanning therebetween together forming a receptacle such as the trough 806. The web may include protrusion on a portion thereof. The flanges 802, 804 and web 810 may form extend in a closed loop so as to form an aperture 808. An interlocking portion 800 may be formed, such as by thermoforming. The interlocking portion 800 may be converted into an interlocking portion 820 by forming one or more apertures 812 therein. For example, an interlocking portion 800 may be machined post-forming to form the apertures 812. In other examples, an interlocking portion having apertures may be formed of different portions than a portion 800. FIG. 59 illustrates a portion of a subassembly 830 as may be formed by stacking one or more interlocking portions 800, 820. The interlocking portions may be joined at one or more joints 822, which may be joints be as disclosed herein. The joints 822 may be joined such that the interlocking portions 820 form a face 823 or a corner portion 825. The joints 822 may be aligned such that the face 823 and/or the corner portion 825 is substantially uniform. In some examples, the face 832 may be substantially planar. The corner portion 825 may be a substantially smooth, uniform arc. The face 823 and/or the corner portion 825 may form other shapes as desired. As shown in FIG. 60, the interlocking portion 800 may be configured such that a web 810 of one interlocking portion 800, 820 may be received in receptacle such as the trough 806 of another interlocking portion 800, 820. For example in an interlocking structure, the trough 806 may be wider than the web 810, such that the web 810 of one interlocking portion is received in the trough 806 of another interlocking portion, forming an overlapping region therebetween. In another example of an interlocking structure, the trough 806 may be the same size or narrower than a web of another interlocking portion, forming an interference fit therebetween. An interlocking structure may be formed such that interlocking portions engage one another at other types of joints such as butt joints, stepped, tongue and groove, shear, scarf joints, and the like such as described with respect to FIGS. 11 and 12. As such, the interlocking portions 800, 820 may be built up to form an insulating container. The length of an insulating container so formed may be modular and adapted for certain applications. Such interlocking portions 800, 820 may enable lower-cost production of insulating containers of various sizes. For example with several press tools, and subassemblies 830 of various numbers of interlocking portions (e.g., three portions, ten portions, twenty portions or more) stacked together, insulating containers may be formed of many different sizes, without the cost of additional tooling. As shown for example in FIG. 62, a subassembly 840 may include one or more interlocking portions 820 and an interlocking portion 800 configured as a cap or end portion.

FIG. 61 shows an example of an interlocking portion 850 including flanges 802, 804 and a web 810 as described. The interlocking portion 850 may be formed of two or more pieces 852, 854. One of the pieces of the interlocking portion 850 may be configured to interlock with another complementary piece of the interlocking portion 850. For example, the portion 854 may include a trough or other receptacle 806 adapted to receive a protrusion such as a tang 853 of the portion 852. The portions 853 and 854 may be nested together and joined as disclosed herein. The interlocking portion 850 may be stacked and/or joined to other interlocking portions as desired. In some examples, a split line between the portions 852, 854 may be offset of located in other areas between different interlocking portions. For example, an interlocking portion 800 also including the two-piece construction of the interlocking portion 850 may be split along a line substantially perpendicular to the split line of the interlocking portion 850 when stacked.

FIGS. 63 and 64 show an insulating container 900 formed of one or more interlocking portions 900, 920, which may have features similar to those of the interlocking portions 800, 820. An interlocking portion 920 may be formed from a different tool than the interlocking portion 900. The interlocking portion 920 may include a flange 902 and an opposing flange 904. The flanges may be joined by a web 910 and include an aperture 912 formed in the web 910. As discussed above, the web 910 may include a protrusion adapted to be received in a receptacle of another interlocking portion 900, or 920. The portions 900, 920 may be joined at one or more joints 922 to adjacent interlocking portions 900, 920. One or more upper flange portions 913 may be provided, such as to interface with a lid, like the lid 400.

FIGS. 65A and 65B illustrate examples of methods 1000 and 1008, respectively, to reduce, remove, or change the draft of a molded part. In some implementations it may be beneficial to mold parts in a mold that includes a draft such that the part may be removed easily from the mold when molding is complete. However, the draft of the molded part may present difficulties in building up an assembly from such parts. See, for example, the insulating containers and parts thereof described with respect to FIG. 57-64 or 66A-71C. FIGS. 66A-67B illustrate the use of the methods 1000 and 1008 for example with interlocking portions 1016. The methods 1000, 1008 may be used with interlocking portions 800, 820, 900, 920, 1016, 1200, and/or 1300. However, for clarity, the methods are described with respect to the interlocking portions 1016 shown for example in FIGS. 66A-68F. The interlocking portions 1016 may be similar to the interlocking portions 800, 820, 900, 920, 1200, 1300 described herein. For example, the interlocking portions 1016 may include flanges 1018 similar to the flanges 802, and may include web portions 1020 similar to the web portions 810. Apertures 1021 may be formed between the web portions 1020. Interlocking portions 1016 may be joined together at one or more joints 1022 similar to joints 822 to form a subassembly 1030 that may be similar to the subassembly 830. For example, interlocking portions 1016 may be joined at a joint 1022 to form a subassembly 1030 (see, e.g., FIG. 59 or 66C). It may be desirable for the joints 822, 1022 to be flush so as to form a uniform face 823, 1023. The face 823 or the face 1023 may be substantially planar. Similarly, the joints 822, 1022 may be flush so as to form a uniform corner portion 825 or 1025 (see, e.g., FIG. 68F).

The method 1000 may begin in operation 1002 and an interlocking portion 1016 is molded. The interlocking portion 1016 may be molded by thermoforming techniques as described for example with respect to FIGS. 4A, 4B, and 5 as discussed herein. In operation 1002, the interlocking portion 1016 may additionally or alternately be molded by other suitable methods such as injection molding, rotational molding, blow molding, extrusion molding, compression molding, or the like.

The method 1000 may proceed to operation 1004 and the interlocking portion 1016 is removed from the mold. The interlocking portion 1016 may be removed from the mold by any suitable method that can separate the mold from the part without damage to either the mold or the part. In some examples, the mold may include separable sections that are disconnected from one another to release the interlocking portion. In other examples, the mold may include an ejector mechanism such as an ejector pin that pushes a finished part from a mold. In other examples, such as extrusion molding, the part may be extruded through or pass by a mold as it is formed.

The method 1000 may proceed to operation 1006 and the interlocking portion is remolded to remove, reduce or otherwise change the draft of the molded part. For example, the part may be inserted into a secondary mold that has a reduced or zero draft angle. A plug or other tool 2 may be inserted into the part, such that the part may be compressed between the mold and the plug. The part may be heated to allow the shape of the part to change to achieve the desired reduced draft. Either or both of the plug and/or mold may be heated. For example, when the part is formed of a FRTP material, the part may be heated to or above the glass transition temperature of the thermoplastic matrix of the material. For example, the part may be heated to the glass transition temperature, a rubbery state temperature, a rubbery flow temperature, or a viscous flow temperature of the thermoplastic. For example, if a PEEK matrix is used, the part may be heated above about 140° C., a typical glass transition temperature for PEEK materials. In some examples, a material may have a glass transition region that includes or is below ambient conditions. For example, polypropylene may have a glass transition temperature of about −20° C. to about −10° C. In operation 1006, the part may be compressed between a mold and a plug at ambient conditions (e.g., about 25° C.) and the part may not be heated. The temperature to which a part is heated may vary depending on the amount of fiber in the material. In operation 1006, a part may be held in a mold for a sufficient time to allow the draft to be reduced or removed. In some examples, a mold may have a negative draft such that when a part is removed from the mold, an elastic rebound of the part may cause it to have a reduced draft. In some implementations, the reduced draft may be substantially no draft such that the draft is removed.

See for example, FIG. 66A showing an interlocking portion 1016 including a flange portion with a draft 1019. In operation 1006, the flange 1018 may be compressed, deformed, and/or heated as described with respect to the method 1000 and indicated by arrows 1011 such that the draft 1019 is reduced, changed, or removed. For example, after operation 1006, the interlocking portion 1016 may have a form shown for example in FIG. 66B with the draft reduced or substantially removed. As shown in FIG. 66C, two or more interlocking portions 1016 may be assembled to one another and joined to form a subassembly 1030.

FIG. 65B illustrates a method 1008 to reduce, remove, or change the draft of a molded part. The part may be molded in operation 1010, which may be as described with respect to operation 1002. Example interlocking portions 1016 formed by the method 1008 are shown for example in FIGS. 67A and 67B. The method 1008 may proceed to operation 1012, and an interlocking portion 1016 may be assembled with another interlocking portion 1016 and/or a subassembly 1030. See for example, FIGS. 67A and 67B, showing an example of two interlocking portions 1016 that may be assembled together to begin to form a subassembly 1030. For example, the web 1020 of one interlocking portion 1016 may be received in a receptacle such as the trough 1017 of another interlocking portion 1016. The interlocking portions 1016 may be held in a jig, fixture, mold or other suitable tool to remove, reduce, or change the draft of a part and to form a flush joint 1022. For example, as indicated by the arrows 1011, the tool may elastically or plastically deform a flange 1018 of one interlocking portion 1016 against the web 1020 of a second interlocking portion 1016 into which the first interlocking portion is received. This process may be repeated with multiple interlocking portions as appropriate, depending on the size of the subassembly 1030 desired.

The method 1008 may proceed to operation 1014 and the interlocking portions 1016 may be fastened to one another, or an interlocking portion 1016 may be fastened to a subassembly 1030. See FIGS. 67A and 67B. For example, the two or more interlocking portions 1016 may be attached to one another by an adhesive, or may be welded to one another using any suitable welding technology (e.g., ultrasonic welding, friction stir welding, or the like). The interlocking portions 1016 may be fastened such that the joint 1022 is substantially flush or smooth and the assembly forms a face 1023 and/or corner portions 1025 as described with respect to the method 1000. After the interlocking portions 1016 are fastened to one another or an interlocking portion 1016 is fastened to a subassembly 1030, the assembled parts may be removed from the jig, fixture, mold or other suitable tool.

FIGS. 68A-68F illustrate examples of interlocking portions 1016 that may be assembled in an assembly 1030 such that the parts form suitable structures such that the webs 1020 form spacers. The interlocking portions may form an aperture 1108 similar to the aperture 808 described with respect to the interlocking portion 820. The spacers 1020 may be similar in function, structure, and/or materials as the spacers 620, 626, 628 previously described. The orientation of the interlocking portions 1016 may be alternated or rotated such that a single mold may be used to make multiple interlocking portions 1016 to form the assembly 1030.

As shown for example in FIG. 68A, the spacers 1020 may be arranged in one or more spacer groups 1100 a, 1100 b, 1100 c, 1100 d. The spacer groups may be disposed on respective sides of the flange 1018 of the interlocking portion 1016. See for example spacer group 1100 a disposed on a first side of the interlocking portion 1016, and a spacer group 1100 c disposed on an opposite side of the interlocking portion 1016 from the group 1100 a. Spacer groups 1100 b and 1100 d may be arranged similarly. FIG. 68B shows an interlocking portion 1016 that may be formed with the same mold as the interlocking portion 1016 shown in FIG. 68A. The interlocking portion of FIG. 68B may include spacer groups 1110 a, 1110 b, 1110 c, 1110 d which may be similar to spacer groups 1100 a, 1100 b, 1100 c, 1100 d. FIG. 68C shows a side elevation view of the interlocking portions 1016 of FIGS. 68A and 68B.

As shown for example in FIGS. 68D-68F, the interlocking portions 1016 may be assembled into a subassembly 1030 such that the spacer groups 1100 a, 1100 b, 1100 c, 1100 d and 1110 a, 1110 b, 1110 c, 1110 d are arranged cooperatively to form a staggered pattern of spacers in the subassembly 1030. For example, when interlocking portions 1016 are stacked in alternating orientations, the spacers may be arranged to form a repeating, staggered pattern of spacers distributed around the subassembly 1030. Such an arrangement may serve to increase the strength of the subassembly 1030 (e.g., to withstand the forces of a vacuum formed in the trough 1017 as described for example with respect to FIGS. 52 and 53) and without the additional cost of multiple molds.

FIGS. 69A-71C illustrate examples of methods of forming an interlocking portion 1200. The interlocking portion 1200 may have similar features, functions, and/or materials as discussed with respect to the interlocking portions 800, 820, 900, 920, 1016, and/or 1300 as disclosed herein. The methods illustrated for example in FIGS. 69A-71C may be used to form any of the interlocking portions 800, 820, 900, 920, 1016, 1200, and/or 1300. As shown in FIGS. 69A, 70A, 70B, and 71A, an interlocking portion 1200 may include with a flash section 1202. The flash section 1202 may be removed from the interlocking portion 1200 to form the spacers 1220 as shown for example in FIGS. 69B, 70C, 71B and/or 71C. Apertures 1221 may be formed between the spacers 1220. For example, the flash section 1202 may be removed by machining or facing the flash section (e.g., on an end mill, computer-numerical controlled (CNC) machine, or the like). In other examples, the flash section may be formed with one or more lines of weakness therein such that the flash section may be broken off from the interlocking portion 1200.

FIGS. 72A-72C and 74 illustrate an example of a method of forming any of the parts of an insulating container disclosed herein. FIG. 72A shows a plan view of an interlocking portion 1300. The interlocking portion 1300 may have similar features, functions, and/or materials as discussed with respect to the interlocking portions 800, 820, 900, 920, 1016 and/or 1200 as disclosed herein. The methods may be used to form any of the interlocking portions 800, 820, 900, 920, 1016, 1200, and/or 1300. The interlocking portion 1300 may include a perimeter 1308 that may be disposed at any location within the interlocking portion 1308. For example, as shown in FIG. 72A, the perimeter 1308 may be disposed approximately midway between an inner flange wall 1320 and an external flange wall 1318. In various examples, the perimeter 1308 may be defined at or between either of the inner flange wall 1320 and the external flange wall 1318. The perimeter 1308 may be any suitable shape to form a part of an insulating container. For example, as shown in FIGS. 72A-72C, the perimeter may have the shape of a rounded rectangle. The perimeter may be circular, oval, square, rectangular, hexagonal, or an irregular shape as desired.

The perimeter 1308 may have a normal direction 1306 defined with respect thereto. The normal direction 1306 may be normal to the perimeter 1308 at any point along the perimeter 1308. For example, as shown in FIG. 72A, the normal direction 1306A may be aligned with a radius of a corner of the perimeter 1308. Similarly as shown in FIG. 72A, the normal direction 1306B may be aligned normal to a linear portion of the perimeter 1308.

The interlocking portion 1300 may be formed of one or more prepreg elements 1302, such as prepreg elements 1302A, 1302B. The prepreg elements 1302A, 1302B may be formed of an FRTP material and may have fibers 1304A, 1304B oriented in a longitudinal direction along the fibers. The longitudinal direction of the fibers may be aligned with a direction relative to the perimeter 1308 of the interlocking portion 1300. For example, the longitudinal direction of the fibers 1306A may be aligned with the normal direction 1306A. In other examples, the longitudinal direction of the fibers may be aligned with a circumferential direction 1307 of the perimeter 1308, or aligned with directions between the normal 1306 and circumferential 1307 directions. Likewise, the longitudinal direction of the fibers 1306B may be aligned with the normal direction 1306B. As shown in FIGS. 72B and 72C the interlocking portion 1300 may be formed of multiple prepreg elements 1302 with the longitudinal directions of the fibers aligned with the local normal directions 1306 of the perimeter 1308. Two or more of the prepreg elements may overlap. The prepreg portions may be thermoformed as described with respect to FIGS. 4A, 4B, and 5. Such arrangements of fiber longitudinal directions with normal directions 1306 of the interlocking portion 1300 may have advantages when thermoforming the interlocking portion 1300 such as to increase strength, reduce wrinkling, or the like. FIG. 74 shows an example of forming a portion of any insulating container herein. Similar to the methods illustrated in FIGS. 72A-72C, in FIG. 74, a prepreg element 1502 may be used to form an interlocking portion 1500. The interlocking portion 1500 may be similar to the interlocking portion 1300 or any other interlocking portion disclosed herein. In the example shown in FIG. 74, a single prepreg element 1502 may be used to form the interlocking portion 1500 as described above with respect to FIGS. 72A-72C. The prepreg element 1502 may have an aperture 1504 formed therein, such that the finished portion 1500 includes an aperture formed therein.

FIGS. 73A-73D show an example of an insulating container 1400 formed of interlocking portions such as the portions 800, 820, 900, 920, 1016, 1200, 1300, 1402, 1404, 1406, and/or 1408. FIG. 73A shows an exploded view of the insulating container 1400. FIG. 73B shows an isometric view of the insulating container 1400. FIGS. 73B and 73C show section views of the insulating container 1400. One or more of the interlocking portions 1402, 1404, 1406, 1408, 1632 may be oriented as shown in the figures, or may be oriented with the spacers on an upper portion of the interlocking portion rather than a lower portion as shown.

FIGS. 75-81B illustrate an example of an insulating container 1600 which may be similar in many aspects to other insulating containers disclosed herein. In particular, the insulating container 1600 may be built up from one or more interlocking portions similar to the insulating container 1400. More or fewer interlocking portions 1632 may be used to scale the size of the insulating container 1600 to relatively larger or smaller sizes. The insulating container 1600 includes a top portion or lid 1610, a body 1630, and a base 1650. The lid 1610 may be removably attached to the body 1630, such as with a latch, hinge, or other securement structure so that the internal compartment 1694 of the insulating container 1600 can be selectively accessed. As shown for example in FIG. 75, the body 1630 may be build up from one or more interlocking portions 1632. The interlocking portions 1632 may be joined to one another at one or more respective joints 1634. An interlocking portion 1632 may be joined to the base at one or more joints 1636. An interlocking portion 1632 may be joined to a portion of the lid 1610 by one or more joints 1638. Any of the joints 1634, 1636, and/or 1638 may be flush joints that form a uniform face.

The interlocking portion 1632 may have similar features, functions, and/or materials as discussed with respect to the interlocking portions 800, 820, 900, 920, 1016, 1200, and/or 1300 as disclosed herein. The interlocking portions 1632 may be any suitable shape that can form a storage compartment 1694 for the insulating container 1600. The storage compartment 1694 may be similar to any other storage compartment disclosed herein. For example, the interlocking portions 1632 may be rounded rectangles, squares, circles, other polygons, or other irregular shapes.

With reference to FIGS. 76 and 77, the interlocking portions 1632 may be formed from one or more walls 1629 a and 1629 b spaced apart from one another so as to form a portion of an insulation chamber n. For example, an outer wall 1629 a may form an outer surface of the body 1630 and an inner wall 1629 b may form an inner surface of the storage compartment 1694. The walls 1629 a,b may be spaced apart from one another without the use of a web portion (e.g., without a web portion similar to the web 810 or other similar webs). For example, spacing of the walls 1629 a,b may be accomplished by the interface of the lid 1610 and/or base 1650 and the interlocking portions 1632. An advantage of the insulating container 1600 may be a reduction of the number of thermal conduction paths between the outer and inner walls 1629 a,b (i.e., web portions). In some embodiments, the inner and/or outer walls 1629 a,b may form respective singular perimeters. In some embodiments the inner and/or outer walls 1629 a,b of an interlocking portion 1632 may be formed in two or more portions that are joined to one another (e.g., similar to the interlocking portion 850 which may be formed of two or more pieces 852, 854). For example, the inner walls 1629 b of an interlocking portion 1632 may be formed of two portions joined at a joint 1641. The interlocking portions 1632 may be formed of any material and with an method disclosed herein.

FIG. 78 shows examples of portions of the base 1650. In some embodiments, the base 1650 may include an inner portion 1654 and an outer portion 1652. The inner portion 1654 may form a floor of the internal compartment 1694. The outer portion 1652 may form a support surface for the insulating container 1600 suitable to support the container 1600 on a support surface such as the ground, a floor, or a portion of a vehicle (e.g., bed of a truck). The inner and/or outer portions 1652, 1654 may be formed of respective panel structures. The panels may be formed of any material disclosed herein. The panels may be formed by thin bodies. The panels may each have a first inner face and a second opposing outer face spaced apart by the thickness dimension of the panel. The panels may each be entirely or partially planar, entirely, or partially curved in a single plane, entirely or partially curved in multiple planes, and/or a combination. The panels may define peripheral edges defining the shape of the panel, and along which a panel may be at least partially attached to an adjacent panel as noted below. Either or both of the panels 1652, 1654 may be formed of a single piece of material such as by using the methods disclosed herein.

The inner portion 1654 may have a planar portion 1666 and a flange portion 1665 extending proud of the planar v 1666. A recess 1668 may be formed by the extension of the flange portion 1665 from the planar portion 1666. The flange portion 1665 may include corner portions 1663 a, 1663 b, 1663 c, 1663 d. The corner portions 1663 may be rounded corners (e.g., filleted) as shown for example, in FIG. 78. In some embodiments, the corner portions 1663 may be sharp corners or other shapes. The corner portions 1663 may be joined by respective span portions 1664 a, 1664 b, 1664 c, 1664 d. For example, the corner portions 1663 a and 1663 b may be joined by a span portion 1664 a. In the example shown in FIG. 78, the corner portions 1663 may be such that they position the respective span portions 1664 joined thereto at about a 90° angle such that the flange portion 1653 forms a periphery. In other embodiments, the corner portions 1663 may be such that they position the respective span portions 1664 joined thereto at other angles, such that the flange portion 1665 forms a periphery. The flange portion 1665 may have an edge 1667. As discussed below, the edge 1667 may aid in forming the joint 1636 that joins the base 1650 to the body 1630.

The outer portion 1652 may have a planar portion 1658 and a flange portion 1653 extending proud of the planar portion 1658. A recess 1659 may be formed by the extension of the flange portion 1653 from the planar portion 1658. The flange portion 1653 may include corner portions 1657 a, 1657 b, 1657 c, 1657 d. The corner portions 1657 may be rounded corners (e.g., filleted) as shown for example, in FIG. 78. In some embodiments, the corner portions 1657 may be sharp corners or other shapes. The corner portions 1657 may be joined by respective span portions 1656 a, 1656 b, 1656 c, 1656 d. For example, the corner portions 1663 a and 1663 b may be joined by a span portion 1656 a. In the example shown in FIG. 78, the corner portions 1657 may be such that they position the respective span portions 1656 adjacent thereto at about a 90° angle such that the flange portion 1653 forms a periphery. In other embodiments, the corner portions 1657 may be such that they position the respective span portions 1656 joined thereto at other angles, such that the flange portion 1653 forms a periphery. The flange portion 1653 may have an edge 1655. As discussed below, the edge 1655 may aid in forming the joint 1636 that joins the base 1650 to the body 1630.

With reference to FIG. 79, examples of portions of the lid portion 1610 are shown. The lid portion 1610 may include an upper portion 1612 that forms the top of the lid portion 1610. The lid portion 1610 may include a lower portion 1614 coupled to the upper portion 1612. The upper and lower portions 1612, 1614 may be formed of respective panel structures. The panels may be formed of any material disclosed herein. The panels may be formed by thin bodies. The panels may each have a first inner face and a second opposing outer face spaced apart by the thickness dimension of the panel. The panels may each be entirely or partially planar, entirely, or partially curved in a single plane, entirely or partially curved in multiple planes, and/or a combination. The panels may define peripheral edges defining the shape of the panel, and along which a panel may be at least partially attached to an adjacent panel as noted below. Either or both of the panels 1612, 1614 may be formed of a single piece of material such as by using the methods disclosed herein.

The upper portion 1612 may have a planar portion 1621 and a flange portion 1623 extending proud of the planar portion 1621. A recess may be formed by the extension of the flange portion 1623 from the planar portion 1621. The flange portion 1623 may include corner portions 1620 a, 1620 b, 1620 c, 1620 d. The corner portions 1620 may be rounded corners (e.g., filleted) as shown for example, in FIG. 79. In some embodiments, the corner portions 1620 may be sharp corners or other shapes. The corner portions 1620 may be joined by respective span portions 1622 a, 1622 b, 1622 c, 1622 d. For example, the corner portions 1620 a and 1620 b may be joined by a span portion 1622 a. In the example shown in FIG. 79, the corner portions 1620 may be such that they position the respective span portions 1622 adjacent thereto at about a 90° angle, such that the flange portion 1623 forms a periphery. In other embodiments, the corner portions 1620 may be such that they position the respective span portions 1622 joined thereto at other angles, such that the flange portion 1623 forms a periphery. The flange portion 1623 may have an edge 1619. As discussed below, the edge 1619 may aid in forming the joint 1638 that joins a portion of the lid 1610 to the body 1630.

The lower portion 1614 may have a planar portion 1635 and a flange portion 1615 extending proud of the planar portion 1635. A recess may be formed by the extension of the flange portion 1615 from the planar portion 1635. The flange portion 1615 may include corner portions 1624 a, 1624 b, 1624 c, 1624 d. The corner portions 1624 may be rounded corners (e.g., filleted) as shown for example, in FIG. 79. In some embodiments, the corner portions 1624 may be sharp corners or other shapes. The corner portions 1624 may be joined by respective span portions 1626 a, 1626 b, 1626 c, 1626 d. For example, the corner portions 1624 b and 1624 c may be joined by a span portion 1626 a. In the example shown in FIG. 79, the corner portions 1624 may be such that they position the respective span portions 1626 adjacent thereto at about a 90° angle, such that the flange portion 1615 forms a periphery. In other embodiments, the corner portions 1624 may be such that they position the respective span portions 1626 joined thereto at other angles, such that the flange portion 1615 forms a periphery. The flange portion 1615 may have an edge 1617. As discussed below, the edge 1617 may aid in forming the joint 1638 that joins a portion of the lid 1610 to the body 1630. With reference to FIGS. 80A and 80B, the flange portion 1615 of the lower portion 1614 may include inner portion 1660 b and outer portion 1660 a joined by a lateral web 1627. The inner portion 1660 b, the outer portion 1660 a, and the web portion 1627 may form a receptacle 1648. The inner portion 1660 b may have a shoulder portion 1647 extending laterally therefrom. A step 1651 may extend from the shoulder and join the shoulder 1647 to the planar portion 1635. The step 1651 and the edge 1619 may form an interface between the upper portion 1612 and the lower portion 1614 of the lid 1610 and the rim 1616. A seal, such as any seal disclosed herein may be used to couple the upper portion 1612 and the lower portion 1614 of the lid 1610 to the rim 1616. A seal may be received in the receptacle 1648.

With reference to FIGS. 79, 80A, and 80B, the lid 1610 may be selectively attachable to a rim portion 1616 joined to the body 1630. The rim portion 1616 may have peripheral flange portions 1642 joined by a web portion 1644. A protrusion 1643 may extend from one or more of the flange portions 1642. A recess 1646 may be formed by the extension of the flange portion 1642 from the web portion 1644. The rim portion 1616 may include corner portions 1628 a, 1628 b, 1628 c, 1628 d. The corner portions 1628 may be rounded corners (e.g., filleted) as shown for example, in FIG. 79. In some embodiments, the corner portions 1628 may be sharp corners or other shapes. The corner portions 1628 may be joined by respective span portions 1639 a, 1639 b, 1639 c, 1639 d. For example, the corner portions 1628 b and 1628 c may be joined by a span portion 1639 b. In the example shown in FIG. 79, the corner portions 1628 may be such that they position the respective span portions 1639 adjacent thereto at about a 90° angle, such that the rim portion 1616 forms a periphery. In other embodiments, the corner portions 1628 may be such that they position the respective span portions 1639 joined thereto at other angles, such that the rim portion 1616 forms a periphery. The flange portion 1642 may be wider than the protrusions 1643, such that one or more shoulders 1645 are formed therebetween. The protrusions 1643 and/or shoulders 1645 may aid in forming the joint 1638 that joins a portion of the rim 1616 to the body 1630. The rim portion 1616 may form a periphery with an aperture 1637 defined therein. The aperture 1637 may be suitable to enable access to the internal compartment of the insulating container 1600 when the rim portion 1616 is coupled to the body 1630 at an interlocking portion 1632.

A receptacle 1674 may be formed between the outer wall 1629 a and the inner wall 1629 b. The protrusions 1643 of the rim portion 1616 may be received in the recess 1646. The shoulders 1645 may interface with the upper edges of the interlocking portion 1632 coupled to the rim portion 1616. The shoulders 1645 may form a stop against the upper edges of the walls 1629 a, 1629 b. The rim portion 1616 may act as a spacer that positions the wall 1629 a with respect to the wall 1629 b. The joint 1638 may be formed by contact of the protrusions 1643 and/or the shoulders with the respective walls 1629 a,b. The rim 1616 may be joined to the walls 1629 a, 1629 b by any suitable method disclosed herein, such as with an adhesive or by welding.

With reference to FIGS. 81A and 81B, an interlocking portion 1632 may be joined to the base 1650 at a joint 1636. The outer wall 1629 a and/or inner wall 1629 b may include respective protrusions 1672 that extend inward (with respect to the outer wall 1629 a) and/or outward (with respect to the inner wall 1629 b). The respective protrusions 1672 may form shoulders 1670 on the respective inner and outer walls. The inner portion 1654 of the base 1650 and the outer portion 1652 of the base 1650 may form a receptacle 1649 therebetween. The protrusions 1672 may be received within the receptacle 1649 to form the joint 1636. The shoulders 1670 may interface with the edge 1667 of the inner portion 1654 and the edge 1655 of the outer portion 1652. The shoulders 1670 may form a stop against the upper edges 1667 and 1655. The inner portion 1654 and the outer portion 1652 may act as a spacer that positions the wall 1629 a with respect to the wall 1629 b. The joint 1636 may be formed by contact of the protrusions 1672 and/or the shoulders 1670 with the respective walls 1629 a,b. The inner portion 1654 and the outer portion 1652 may be joined to the walls 1629 a, 1629 b by any suitable method disclosed herein, such as with an adhesive or by welding. As shown in FIGS. 76 and 77, a first interlocking portion 1632 may be coupled to a second interlocking portion at a joint 1634 similar to the joint 1636. For example, the protrusions 1672 of an upper interlocking portion 1632 may be received in the recess 1674 formed by the inner wall 1629 b and outer wall 1629 b of a lower interlocking portion 1632. The shoulders 1645 of the upper interlocking portion may interface with the upper edges of the walls of the lower interlocking portion.

As shown for example in FIGS. 76 and 77, The upper portion 1612 and the lower portion 1614 of the lid 1610 together may form an insulation chamber 1618 therebetween. Likewise, the inner portions 1654 and outer portion 1652 of the base 1650 may together form an insulation chamber 1618 therebetween. The inner wall 1629 b and outer wall 1629 a of the interlocking portions 1632 may form an insulation chamber therebetween. The insulation chambers 1618 may be in fluid communication with one another, or may be separated from one another. For example, a single insulation chamber 1618 may be formed between the one or more interlocking portions 1632 and the base portion. The insulation chambers 1618 may be suitable to contain an insulating material 1662 that may be similar to any insulating material disclosed herein. For example, the insulating material 1662 may be foam, foil, ceramic, silica fibers, ceramic, glass, or the like. The insulating material 1662 may be a vacuum. For example, the insulation chamber 1618 may be suitable to contain a vacuum. An advantage of the insulating container 1600 may be the reduction of thermal shunts or conduction paths between the environment and the internal compartment 1964, thus increasing insulating capabilities of the insulating container 1600 with respect to other insulating containers in the art. For example, the insulating container 1600 may have an insulation chamber 1618 that insulates not only the span sections of the lid 1610, the interlocking portions 1632 of the body 1630, but also the bottom of the insulating container 1600 and the corner portions between adjacent span portions.

Any of the portions of an insulating container disclosed herein may be formed of one or more prepreg elements. For example the interlocking portions 1632, the lid portion 1610, the body portion 1630, and/or the base portion 1650 may be formed of one or more prepreg elements 1302, such as prepreg elements 1302A, 1302B and/or 1500. The prepreg elements may be formed of an FRTP material and may have fibers oriented in a longitudinal direction along the element. Some components may define a hoop direction that extends along a circumference of the component. For example, the interlocking portions 1632, the walls 1629 a and 1629 b, the rim portion 1616, the inner portion 1654, the outer portion 1652, the upper portion 1612, the lower portion 1614, may have a hoop direction 1683 that extends along the circumference thereof. See, e.g., the hoop direction 1683 shown for example in FIGS. 75-77 with respect to the interlocking portions 1632. In some embodiments, the fibers fiber-reinforced material may be aligned with the hoop direction 1683. Such an alignment may be beneficial to contain vacuum in the insulation chambers, and/or to aid in the structural strength of the container. Such components may be vacuum formed or pressure formed according to any suitable method that can align the fibers with the hoop direction 1683. Such components may be joined together by such methods as welding or the use of adhesives to form an insulated container according to the present disclosure.

A joint between interlocking portions, such as a joint 822, 922, 1022, 1634, 1636, and/or 1638 may increase the strength and/or stiffness of an insulating container. For example the joint 822, 922, 1022 between a receptacle 906, 1017 and web 910, 1020 of adjacent interlocking portions may increase the hoop strength of the insulating container such as by adding additional material near the joints 822, 922, 1022. Increased strength may aid in containing a vacuum in the insulation compartment formed by the joined interlocking portions.

Interlocked interlocking portions 800, 820, 900, 920, 1016, 1200, 1300, and/or 1634 may form one or more internal compartments, insulation compartments, sub-compartments, or internal insulation compartments as disclosed herein and suitable to contain an insulating material or a vacuum. The insulation material may flow through the apertures 812, 912 to adjacent interlocking portions. For example, the apertures 812, 912, 1021, 1221 may be in fluid communication with one another such that the troughs of connected interlocking portions form a single continuous insulation compartment that may be evacuated of air to form a vacuum. In other examples, the apertures 812, 912, 1021, 1221 may form multiple, separate insulation compartments that may be evacuated of air to form a vacuum. Apertures 812, 912 may enable weight savings while allowing a vacuum to be drawn through adjacent interlocking portions.

Various theories, methods, are provided herein. These systems are provided for better understanding of the structures and configurations described. Unless specifically claimed, the systems are not limiting regardless of current accuracy or subsequent clarifications or understandings of the structures and configurations that may be determined by persons of ordinary skill in the art.

The above specification, examples and data provide a complete description of the structure and use of exemplary embodiments of the invention as defined in the claims. Although various embodiments of the claimed invention have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of the claimed invention. Other embodiments are therefore contemplated. For example, while some embodiments specify particular relationships between parts of the system, other relationships are contemplated. It is also contemplated that steps to any disclosed method may be performed in any order. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative only of particular embodiments and not limiting. Changes in detail or structure may be made without departing from the basic elements of the invention as defined in the following claims. 

1. An insulating container comprising: a first housing; a second housing coupled to the first housing and defining an insulation compartment therebetween; and an insulating material disposed in the insulation compartment, wherein one of the first housing or the second housing defines an internal compartment and is constructed at least partially of a fiber-reinforced thermoplastic including a reinforcing fiber.
 2. The insulating container of claim 1, wherein the reinforcing fiber comprises at least one of a carbon fiber, a glass fiber, or an aramid fiber.
 3. The insulating container of claim 1, wherein the reinforcing fiber is continuous.
 4. The insulating container of claim, wherein the reinforcing fiber is non-continuous.
 5. The insulating container of claim 4, wherein the non-continuous reinforcing fiber comprises a chopped fiber bulk molding compound. 6.-13. (canceled)
 14. The insulating container of claim 1, wherein one of the first housing or the second housing comprises a fiber-reinforced thermoplastic composite and the other of the first housing or the second housing comprises a non-fiber reinforced material.
 15. The insulating container of claim 1, wherein the first and second housings comprise a fiber reinforced thermoplastic composite.
 16. The insulating container of claim 15, wherein the fiber reinforced thermoplastic composite is a continuous fiber reinforced thermoplastic comprising a continuous fiber.
 17. (canceled)
 18. The insulating container of claim 14, wherein the non-fiber reinforced material comprises a thermoplastic.
 19. The insulating container of claim 14, wherein the non-fiber reinforced material is a metal.
 20. The insulating container of claim 1, wherein one of the first housing or the second housing comprises a plurality of joined pre-formed fiber reinforced thermoplastic sub-structures. 21.-22. (canceled)
 23. The insulating container of claim 1, wherein the insulating material comprises a foam.
 24. The insulating container of claim 1, wherein the insulating material comprises a vacuum. 25.-54. (canceled)
 55. An insulating container comprising: a housing forming an insulation compartment therein and configured to enclose a vacuum, wherein the housing is constructed at least partially of a fiber reinforced thermoplastic. 56.-57. (canceled)
 58. A method of forming a housing of an insulating container comprising: molding a first housing of the insulating container; removing the first housing from a first mold; and remolding the first housing in a second mold to reduce a draft of the housing. 59.-68. (canceled)
 69. An insulating container comprising: an interlocking portion including an inner wall and an outer wall coupled to, and spaced apart from, the inner wall, wherein a first insulation chamber is formed between the inner wall and the outer wall; and a rim portion coupled to respective upper edges of the inner wall and the outer wall. 70.-73. (canceled)
 74. The insulating container of claim 71, wherein at least one of the interlocking portion, the rim portion, the base portion, or the lid portion are constructed at least partially of a fiber-reinforced thermoplastic including a reinforcing fiber.
 75. The insulating container of claim 74, wherein at least one of the interlocking portion, the rim portion, the base portion, or the lid portion is formed of a plurality of overlapping prepreg portions, wherein each of the prepreg portions includes a fiber with a longitudinal direction aligned with a normal direction of a perimeter of the respective portion.
 76. The insulating container of claim 74, wherein at least one of the interlocking portion, the rim portion, the base portion, or the lid portion is formed of a single prepreg portion.
 77. (canceled)
 78. The insulating container of claim 74, wherein at least one of the interlocking portion, the rim portion, the base portion, or the lid portion defines a hoop direction and one or more reinforcing fibers are aligned with the hoop direction.
 79. The insulating container of claim 55 wherein the housing includes a spacer between an inner and outer boundary shells so as to resist an external force of the atmosphere.
 80. The insulating container of claim 69, further comprising: a base portion including an inner portion and an outer portion spaced apart from the inner portion, wherein: the inner wall and the inner portion form an internal compartment, a second insulation chamber is formed between the inner portion and the outer portion, the inner portion and the outer portion are coupled to the respective lower edges of the respective inner wall and outer wall, and the first insulation chamber and the second insulation chamber are in fluid communication with one another to form a third insulation chamber. 